Cellulose acetate butyrate bound zeolite adsorbents

ABSTRACT

An improved adsorbent comprising a crystalline aluminosilicate, method of manufacture of the adsorbent and improved process for separating a component from a feed mixture comprising an aqueous solution of a mixture of different components, such as a mixture of saccharides. In the process the mixture is contacted with the adsorbent, which selectively adsorbs a component from the feed mixture. The adsorbed component is then recovered by contacting the adsorbent with a desorbent material such as water to effect the desorption of the adsorbed component from the adsorbent. There is an undesirable tendency for the silicon constituent of the crystalline aluminosilicate to dissolve in the aqueous system. The improvement to the adsorbent and process comprises the incorporation of a binder material in the adsorbent comprising cellulose acetate butyrate which substantially reduces the undesirable dissolution. The adsorbent is manufactured by mixing together powder of the crystalline aluminosilicate, powders of the binder, and a liquid organic solvent, extruding the mixture into an extrudate and drying the extrudate.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation-in-part of my prior, copendingapplication Ser. No. 48,955 filed June 15, 1979 now U.S. Pat. No.4,248,737. All of the teachings of this prior application areincorporated herein by reference thereto.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of art to which this invention pertains is solid-bedadsorptive separation. More specifically, the invention relates to animproved adsorbent, method of manufacture of the adsorbent and improvedprocess for separating a component from a mixture comprising an aqueoussolution of a mixture of different components which process employs anadsorbent comprising a crystalline aluminosilicate which selectivelyadsorbs a component from the feed mixture.

2. Prior Art

It is known in the separation art that certain crystallinealuminosilicates referred to as zeolites can be used in the separationof a component from an aqueous solution of a mixture of differentcomponents. For example, adsorbents comprising crystallinealuminosilicate are used in the method described in U.S. Patent No.4,014,711 to separate fructose from a mixture of sugars in aqueoussolution including fructose and glucose.

It is also known that crystalline aluminosilicates or zeolites are usedin adsorption processing in the form of agglomerates having highphysical strength and attrition resistance. Methods for forming thecrystalline powders into such agglomerates include the addition of aninorganic binder, generally a clay comprising silicon dioxide andaluminum oxide to the high purity zeolite powder in wet mixture. Theblended clay zeolite mixture is extruded into cylindrical type pelletsor formed into beads which are subsequently calcined in order to convertthe clay to an amorphous binder of considerable mechanical strength. Asbinders, clays of the kaolin type are generally used.

Zeolite crystal and inorganic binder agglomerates have long been knownto have the property of gradually disintegrating as a result ofcontinuous contact with water. This disintegration has been observed asa silicon presence or contamination in the solution in contact with theadsorbent. Such contamination may at times be sufficiently severe toimpart a cloudy appearance to the solution.

I have discovered an improved adsorbent, a method of manufacturing theadsorbent and an improvement to an aqueous separation process whichminimizes the disintegration of the adsorbent and silicon contaminationof the product.

SUMMARY OF THE INVENTION

Accordingly, the objectives of my invention are (1) to provide animprovement to a process for the separation of a component from a feedmixture comprising different components in aqueous solution bycontacting said mixture with an adsorbent comprising a crystallinealuminosilicate so as to minimize the dissolution of the crystallinealuminosilicate and silica contamination of the product; (2) to developan adsorbent composition suitable for use in the process of the firststated objective; and (3) to provide a method of manufacture of suchadsorbent.

In brief summary, my invention is, in one embodiment, an improvedprocess for the separation of a component from a feed mixture comprisingan aqueous solution of a mixture of components by contacting thesolution with an adsorbent comprising a crystalline aluminosilicateexhibiting an adsorptive selectivity towards the component. Thecomponent is thereby selectively adsorbed from the mixture, andthereafter recovered. The silicon constituent of the adsorbent tends todissolve in the solution resulting in the undesirable disintegration ofthe adsorbent. The adsorbent additionally contains a binder materialcomprising cellulose acetate butyrate which substantially reduces theextent of dissolution of the silicon constituent and the extent of thedisintegration of the adsorbent.

In another embodiment, my invention is an adsorbent comprising acrystalline aluminosilicate suitable for use in a process for theseparation of a component from a feed mixture comprising an aqueoussolution of a mixture of components by contacting the solution with theadsorbent. The silicon constituent of the adsorbent tends to dissolve inthe solution resulting in the undesirable disintegration of thecrystalline aluminosilicate. The adsorbent additionally contains abinder material comprising cellulose acetate butyrate whichsubstantially reduces the extent of dissolution of the siliconconstituent and the extent of the disintegration of the adsorbent.

In still another embodiment, my invention is a method for themanufacture of an adsorbent comprising crystalline aluminosilicate and acellulose acetate butyrate binder material suitable for use in a processfor the separation of a component from a feed mixture comprising anaqueous solution of a mixture of components. The method comprises: (a)mixing together a powder of crystalline aluminosilicate, a powder of thebinder and a liquid organic solvent to form a malleable mixture; (b)forming said malleable mixture into discrete formations; (c) removingthe solvent from the formations to obtain hard dry formations; and (d)breaking the hard dry formations into particles of desired sizes.

Other objects and embodiments of my invention encompass details aboutfeed mixtures, adsorbents, solvents, desorbent materials and operatingconditions, all of which are hereinafter disclosed in the followingdiscussions of each of the facets of the present invention.

DESCRIPTION OF THE INVENTION

At the outset the definitions of various terms used throughout thespecification will be useful in making clear the operation, objects andadvantages of my process.

A feed mixture is a mixture containing one or more extract componentsand one or more raffinate components to be separated by my process. Theterm "feed stream" indicates a stream of a feed mixture which passes tothe adsorbent used in the process.

An "extract component" is a component that is more selectively adsorbedby the adsorbent while a "raffinate component" is a component that isless selectively adsorbed. The term "desorbent material" shall meangenerally a material capable of desorbing an extract component. The term"desorbent stream" or "desorbent input stream" indicates the streamthrough which desorbent material passes to the adsorbent. The term"raffinate stream" or "raffinate output stream" means a stream throughwhich a raffinate component is removed from the adsorbent. Thecomposition of the raffinate stream can vary from essentially 100%desorbent material to essentially 100% raffinate components. The term"extract stream" or "extract output stream" shall mean a stream throughwhich an extract material which has been desorbed by a desorbentmaterial is removed from the adsorbent. The composition of the extractstream, likewise, can vary from essentially 100% desorbent material toessentially 100% extract components. At least a portion of the extractstream, and preferably at least a portion of the raffinate stream, fromthe separation process are passed to separation means, typicallyfractionators or evaporators, where at least a portion of desorbentmaterial is separated to produce an extract product and a raffinateproduct. The terms "extract product" and "raffinate product" meanproducts produced by the process containing, respectively, an extractcomponent and a raffinate component in higher concentrations than thosefound in the extract stream and the raffinate stream.

The term "selective pore volume" of the adsorbent is defined as thevolume of the adsorbent which selectively adsorbs an extract componentfrom the feed mixture. The term "non-selective void volume" of theadsorbent is the volume of the adsorbent which does not selectivelyretain an extract component from the feed mixture. This volume includesthe cavities of the adsorbent sites and the interstitial void spacesbetween adsorbent particles. The selective pore volume and thenon-selective void volume are generally expressed in volumetricquantities and are of importance in determining the proper flow rates offluid required to be passed into an operational zone for efficientoperations to take place for a given quantity of adsorbent. Whenadsorbent "passes" into an operational zone (hereinafter defined anddescribed) employed in one embodiment of this process, its non-selectivevoid volume, together with its selective pore volume, carries fluid intothat zone. The non-selective void volume is utilized in determining theamount of fluid which should pass into the same zone in acounter-current direction to the adsorbent to displace the fluid presentin the non-selective void volume. If the fluid flow rate passing into azone is smaller than the non-selective void volume rate of adsorbentmaterial passing into that zone, there is a net entrainment of liquidinto the zone by the adsorbent. Since this net entrainment is a fluidpresent in non-selective void volume of the adsorbent, it, in mostinstances, comprises less selectively retained feed components. Theselective pore volume of an adsorbent can in certain instances adsorbportions of raffinate material from the fluid surrounding the adsorbent,since in certain instances there is competition between extract materialand raffinate material for adsorptive sites within the selective porevolume. If a large quantity of raffinate material with respect toextract material surrounds the adsorbent, raffinate material can becompetitive enough to be adsorbed by the adsorbent.

The so-called "simple sugars" are classified as monosaccharides and arethose sugars which upon hydrolysis do not break down into smallersimpler sugars. One may further classify monosaccharides as aldoses orketoses, depending upon whether they are hydroxy aldehydes or hydroxyketones, and by the number of carbon atoms in the molecule. Most commonand well known are probably the hexoses. Common ketohexoses are fructose(levulose) and sorbose; common aldohexoses are glucose (dextrose),manose and galactose. The term "oligosaccharides," as commonlyunderstood in the art and as used herein, means simple polysaccharidescontaining a known number of constituent monosaccharide units. Anoligosaccharide that breaks up upon hydrolysis into two monosaccharideunits is called a disaccharide, examples being sucrose, maltose, andlactose. Those giving three such units are trisaccharides, of whichraffinose and melezitose are examples. Di-, tri- and tetra-saccharidescomprise practically all of the oligosaccharides. The term"polysaccharide" includes oligosaccharides but usually it refers tocarbohydrate materials of much higher molecular weight, namely, thosethat are capable of breaking up on hydrolysis into a large number ofmonosaccharide units. Typical polysaccharides are starch, glycogen,cellulose and pentosans.

Feed mixtures which can be charged to the process of my invention may,for example, be aqueous solutions of one or more aldoses and one or moreketoses, or one or more monosaccharides and one or moreoligosaccharides. The concentration of solids in the solutions may rangefrom about 0.5 wt.% to about 50 wt.% or more, but preferably will befrom about 5 to about 35 wt.%. Starch syrups such as corn syrup areexamples of feed mixtures which can be charged to my process. Suchsyrups are produced by the partial hydrolysis of starch generally in thepresence of mineral acids or enzymes. Corn syrup produced in this mannerwill typically contain 25 to 75 wt.% solids comprising 90 to 95% glucoseand 5 to 10% maltose and higher oligosaccharides. A portion of theglucose in this corn syrup may be isomerized with an isomerizing enzymeto produce a high-fructose corn syrup, typically comprising 40-45%fructose, 50-55% glucose and 5-10% oligosaccharides, which can also becharged to my process. The pH of the aqueous solution comprising thefeed mixture may be from about 5.0 to about 8.0.

Desorbent materials used in various prior art adsorptive separationprocesses vary depending upon such factors as the type of operationemployed. In the swing-bed system, in which the selectively adsorbedfeed component is removed from the adsorbent by a purge stream,desorbent selection is not as critical and desorbent material comprisinggaseous hydrocarbons such as methane, ethane, etc., or other types ofgases such as nitrogen or hydrogen, may be used at elevated temperaturesor reduced pressures or both to effectively purge the adsorbed feedcomponent from the adsorbent. However, in adsorptive separationprocesses which are generally operated continuously at substantiallyconstant pressures and temperatures to insure liquid phase, thedesorbent material must be judiciously selected to satisfy manycriteria. First, the desorbent material should displace an extractcomponent from the adsorbent with reasonable mass flow rates withoutitself being so strongly adsorbed as to unduly prevent an extractcomponent from displacing the desorbent material in a followingadsorption cycle. Expressed in terms of the selectively (hereinafterdiscussed in more detail), it is preferred that the adsorbent be moreselective for all of the extract components with respect to a raffinatecomponent than it is for the desorbent material with respect to araffinate component. Secondly, desorbent materials must be compatiblewith the particular adsorbent and the particular feed mixture. Morespecifically, they must not reduce or destroy the critical selectivityof the adsorbent for an extract component with respect to a raffinatecomponent. Additionally, desorbent materials should not chemically reactwith or cause a chemical reaction of either an extract component or araffinate component. Both the extract stream and the raffinate streamare typically removed from the adsorbent in admixture with desorbentmaterial and any chemical reaction involving a desorbent material and anextract component or a raffinate component would reduce the purity ofthe extract product or the raffinate product or both. Since both theraffinate stream and the extract stream typically contain desorbentmaterials, desorbent materials should additionally be substances whichare easily separable from the feed mixture that is passed into theprocess. Without a method for separating at least a portion of thedesorbent material present in the extract stream and the raffinatestream, the concentration of an extract component in the extract productand the concentration of a raffinate component in the raffinate productwould not be very high, nor would the desorbent material be availablefor reuse in the process. It is contemplated that at least a portion ofthe desorbent material will be separated from the extract and theraffinate streams by distillation or evaporation, but other separationmethods such as reverse osmosis may also be employed alone or incombination with distillation or evaporation. Since the raffinate andextract products are foodstuffs intended for human consumption,desorbent materials should also be non-toxic. Finally, desorbentmaterials should also be materials which are readily available andtherefore reasonable in cost.

I have found that water having a pH of from about 5.0 to about 8.0satisfies these criteria and is a suitable and preferred desorbentmaterial for my process. The pH of the desorbent material is importantbecause adsorption of a component by the adsorbent, removal of araffinate stream, desorption of the component from the adsorbent andremoval of an extract stream all typically occur in the presence ofdesorbent material. If the desorbent material is too acidic or tooalkaline, chemical reactions of the components are promoted and reactionproducts are produced that can reduce the yield purity of either theextract or raffinate product, or both.

Water pH does of course vary widely depending upon the source of thewater in addition to other factors. Methods of maintaining andcontrolling a desired water pH are, however, well known to those skilledin the art of water treating. Such methods generally comprise adding analkaline compound such as sodium hydroxide or an acid compound such ashydrochloric acid to the water in amounts as necessary to achieve andmaintain the desired pH.

The prior art has recognized that certain characteristics of adsorbentsare highly desirable, if not absolutely necessary, to the successfuloperation of a selective adsorption process. Such characteristics areequally important to this process. Among such characteristics are:adsorptive capacity for some volume of an extract component per volumeof adsorbent; the selective adsorption of an extract component withrespect to a raffinate component and the desorbent material; andsufficiently fast rates of adsorption and desorption of an extractcomponent to and from the adsorbent. Capacity of the adsorbent foradsorbing a specific volume of an extract component is, of course, anecessity; without such capacity the adsorbent is useless for adsorptiveseparation. Furthermore, the higher the adsorbent's capacity for anextract component the better is the adsorbent. Increased capacity of aparticular adsorbent makes it possible to reduce the amount of adsorbentneeded to separate an extract component of known concentration containedin a particular charge rate of feed mixture. A reduction in the amountof adsorbent required for a specific adsorptive separation reduces thecost of the separation process. It is important that the good initialcapacity of the adsorbent be maintained during actual use in theseparation process over some economically desirable life. The secondnecessary adsorbent characteristic is the ability of the adsorbent toseparate components of the feed; or, in other words, that the adsorbentpossesses adsorptive selectivity (B), for one component as compared toanother component. Relative selectivity can be expressed not only forone feed component as compared to another but can also be expressedbetween any feed mixture component and the desorbent material. Theselectivity (B), as used throughout this specification is defined as theratio of the two components of the adsorbed phase over the ratio of thesame two components in the unadsorbed phase at equilibrium conditions.Relative selectivity is shown as Equation 1 below: ##EQU1## where C andD are two components of the feed represented in volume percent and thesubscripts A and U represent the adsorbed and unadsorbed phasesrespectively. The equilibrium conditions were determined when the feedpassing over a bed of adsorbent did not change composition aftercontacting the bed of adsorbent. In other words, there was no nettransfer of material occurring between the unadsorbed and adsorbedphases. Where selectivity of two components approaches 1.0 there is nopreferential adsorption of one component by the adsorbent with respectto the other; they are both adsorbed (or non-adsorbed) to about the samedegree with respect to each other. As the (B) becomes less than orgreater than 1.0 there is a preferential adsorption by the adsorbent forone component with respect to the other. When comparing the selectivityby the adsorbent of one component C over component D, a (B) larger than1.0 indicates preferential adsorption of component C within theadsorbent. A (B) less than 1.0 would indicate that component D ispreferentially adsorbed leaving an unadsorbed phase richer in componentC and an adsorbed phase richer in component D. Ideally, desorbentmaterials should have a selectivity equal to about 1 or slightly lessthan 1 with respect to all extract components so that all of the extractcomponents can be desorbed as a class with reasonable flow rates ofdesorbent material and so that extract components can displace desorbentmaterial in a subsequent adsorption step. While separation of an extractcomponent from a raffinate component is theoretically possible when theselectivity of the adsorbent for the extract component with respect tothe raffinate component is greater than 1.0, it is preferred that suchselectivity be greater than 1.0. Like relative volatility, the higherthe selectivity the easier the separation is to perform. Higherselectivities permit a smaller amount of adsorbent to be used. The thirdimportant characteristic is the rate of exchange of the extractcomponent of the feed mixture material or, in other words, the relativerate of desorption of the extract component. This characteristic relatesdirectly to the amount of desorbent material that must be employed inthe process to recover the extract component from the adsorbent; fasterrates of exchange reduce the amount of desorbent material needed toremove the extract component and therefore permit a reduction in theoperating cost of the process. With faster rates of exchange, lessdesorbent material has to be pumped through the process and separatedfrom the extract stream for reuse in the process.

Adsorbents to be used in the process of this invention will comprisespecific crystalline aluminosilicates or molecular sieves. Particularcrystalline aluminosilicates encompassed by the present inventioninclude crystalline aluminosilicate cage structures in which the aluminaand silica tetrahedra are intimately connected in an open threedimensional network to form cage-like structures with window-like poresof about 8 A free diameter. The tetrahedra are cross-linked by thesharing of oxygen atoms with spaces between the tetrahedra occupied bywater molecules prior to partial or total dehydration of this zeolite.The dehydration of the zeolite results in crystals interlaced with cellshaving molecular dimensions and thus the crystalline aluminosilicatesare often referred to as "molecular sieves," particularly when theseparation which they effect is dependent essentially upon differencesbetween the sizes of the feed molecules as, for instance, when smallernormal paraffin molecules are separated from larger isoparaffinmolecules by using a particular molecular sieve.

In hydrated form, the crystalline aluminosilicates used in the processof my invention generally encompass those zeolites represented by theFormula 1 below:

Formula 1

    M.sub.2/n O:Al.sub.2 O.sub.3 :wSiO.sub.2 :yH.sub.2 O

where "M" is a cation which balances the electrovalence of thealuminum-centered tetrahedra and which is generally referred to as anexchangeable cationic site, "n" represents the valence of the cation,"W" represents the moles of SiO₂, and "y" represents the moles of water.The generalized cation "M" may be monovalent, divalent or trivalent ormixtures thereof.

The prior art has generally recognized that adsorbents comprising X andY zeolites can be used in certain adsorptive separation processes. Thesezeolites are described and defined in U.S. Pat. Nos. 2,882,244 and3,130,007 respectively incorporated herein by reference thereto. The Xzeolite in the hydrated or partially hydrated form can be represented interms of mole oxides as shown in Formula 2 below:

Formula 2

    (0.9±0.2)M.sub.2/n O:Al.sub.2 O.sub.3 :(2.50±0.5)SiO.sub.2 :yH.sub.2 O

where "M" represents at least one cation having a valence of not morethan 3, "n" represents the valence of "M", and "y" is a value up toabout 9 depending upon the identity of "M" and the degree of hydrationof the crystal. As noted from Formula 2, the SiO₂ /Al₂ O₃ mole ratio ofX zeolite is 2.5±0.5. The cation "M" may be one or more of a number ofcations such as hydrogen cation, an alkali metal cation, or an alkalineearth cation, or other selected cations, and is generally referred to asan exchangeable cationic site.

As the X zeolite is initially prepared, the cation "M" is usuallypredominately sodium, that is, the major cation at the exchangeablecationic sites is sodium and the zeolite is therefore referred to as asodium-X zeolite. Depending upon the purity of the reactants used tomake the zeolite, other cations mentioned above may be present, however,as impurities. The Y zeolite in the hydrated or partially hydrated formcan be similarly represented in terms of mole oxides as in Formula 3below:

Formula 3

    (0.9±0.2)M.sub.2/n O:Al.sub.2 O.sub.3 :wSiO.sub.2 :yH.sub.2 O

where "M" is at least one cation having a valence not more than 3, "n"represents the valence of "M", "w" is a value greater than about 3 up toabout 6, and "y" is a value up to about 9 depending up the identity of"M" and the degree of hydration of the crystal. The SiO₂ /Al₂ O₃ moleratio for Y zeolites can thus be from about 3 to about 6. Like the Xzeolite, the cation "M" may be one or more of a variety of cations but,as the Y zeolite is initially prepared, the cation "M" is also usuallypredominately sodium. A Y zeolite containing predominately sodiumcations at the exchangeable cationic sites is therefore referred to as asodium-Y zeolite.

Cations occupying exchangeable cationic sites in the zeolite may bereplaced with other cations by ion exchange methods well known to thosehaving ordinary skill in the field of crystalline aluminosilicates. Suchmethods are generally performed by contacting the zeolite or anadsorbent material containing the zeolite with an aqueous solution ofthe soluble salt of the cation or cations desired to be placed upon thezeolite. After the desired degree of exchange takes place, the sievesare removed from the aqueous solution, washed, and dried to a desiredwater content. By such methods the sodium cations and any non-sodiumcations which might be occupying exchangeable sites as impurities in asodium-X or sodium-Y zeolite can be partially or essentially completelyreplaced with other cations. It is preferred that the zeolite used inthe process of my invention contain cations at exchangeable cationicsites selected from the group consisting of the alkali metals and thealkaline earth metals.

Typically, adsorbents known to the prior art used in separativeprocesses contain zeolite crystals and amorphous material. The zeolitewill typically be present in the adsorbent in amounts ranging from about75 wt.% to about 98 wt.% based on volatile free composition. Volatilefree compositions are generally determined after the adsorbent has beencalcined at 900° C. in order to drive off all volatile matter. Theremainder of the adsorbent will generally be an amorphous inorganicmaterial such as silica, or silica-alumina mixtures or compounds, suchas clays, which material is present in intimate mixture with the smallparticles of the zeolite material. This amorphous material may be anadjunct of the manufacturing process for zeolite (for example,intentionally incomplete purification of either zeolite during itsmanufacture) or it may be added to relatively pure zeolite, but ineither case its usual purpose is as a binder to aid in forming oragglomerating the hard crystalline particles of the zeolite. Normally,the adsorbent will be in the form of particles such as extrudates,aggregates, tablets, macrospheres or granules having a desired particlesize range. The typical adsorbent will have a particle size range ofabout 16-40 mesh (Standard of U.S. Mesh). Examples of zeolites used inadsorbents known to the art, either as is or after cation exchange, are"Molecular Sieves 13X" and "SK-40" both of which are available from theLinde Company, Tonawanda, New York. The first material of coursecontains X zeolite while the latter material contains Y zeolite. It isknown that X or Y zeolites possess the selectivity requirement and othernecessary requirements previously discussed and are therefore suitablefor use in separation processes.

In contradistinction to adsorbents known to the art, the adsorbent of myinvention has incorporated therein a water permeable binder materialcomprising the organic polymer cellulose acetate butyrate. To be waterpermeable, the binder material when a dry solid, will have throughoutits mass small void spaces and channels which will allow an aqueoussolution to penetrate it and thereby come into contact with the zeoliteparticles bound by it. The preferred concentration of the celluloseacetate butyrate in the adsorbent is from about 2.0 to about 50.0 wt.%.

Like some of the above discussed adsorbents of the known art, theadsorbent of my invention is in the form of particles having a particlessize range of about 16-80 mesh (Standard U.S. Mesh). Unlike the knownart adsorbents, however, the adsorbents of my invention do not requirecalcining, and, most important, achieve substantially reduceddisintegration and silicon contamination of the product stream when usedin the process of my invention. The reduced disintegration results inminimization of the undesirable increase in pressure drop through thecolumn in which the adsorbent is packed as compared to the inevitablehigh increase associated with the adsorbents of the known art.

The adsorbent of my invention is manufactured by mixing together powderof the crystalline aluminosilicate, powder of the cellulose acetatebutyrate binder, and a liquid organic solvent to make the mixturemalleable, forming the mixture into discrete formations, removing thesolvent from the formations and breaking the formations into the desiredsized particles. The forming of the malleable mixture is preferably doneby extrusion. The aluminosilicate and binder powders may first be mixedtogether and the solvent added to the powder mixture, or the binderpowder may be first dissolved in the solvent and the aluminosilicatepowder added to the solution. Preferred liquid organic solvents areacetic acid, p-dioxane, methyl-ethyl ketone, acetone, 2-heptanone, or5-methyl-2-hexanone. The solvent is removed from the formations eitherby water washing followed by drying at a temperature not exceeding about140° C., or by just drying at that temperature. The formations arebroken into particles having a preferred size such that the particleswill pass through a No. 16 screen and be retained on a No. 80 screen maybe added to the aluminosilicate-solvent-binder mixture. The particlesmay be further treated to effect ion exchange between cations atexchangeable cationic sites on the crystalline aluminosilicate in theparticles and cations preferably selected from the group consisting ofalkali metals and alkali earth metals.

The adsorbent may be employed in the form of a dense compact fixed bedwhich is alternatively contacted with the feed mixture and desorbentmaterials. In the simplest embodiment of the invention, the adsorbent isemployed in the form of a single static bed in which case the process isonly semi-continuous. In another embodiment, a set of two or more staticbeds may be employed in fixed-bed contacting with appropriate valving sothat the feed mixture is passed through one or more adsorbent beds whilethe desorbent materials can be passed through one or more of the otherbeds in the set. The flow of feed mixture and desorbent materials may beeither up or down through the desorbent. Any of the conventionalapparatus employed in static bed fluid-solid contacting may be used.

Counter-current moving-bed or simulated moving-bed counter-current flowsystems, however, have a much greater separation efficiency than fixedadsorbent bed systems and are therefore preferred for use in myseparation process. In the moving-bed or simulated moving-bed processesthe adsorption and desorption operations are continuously taking placewhich allows both continuous production of an extract and a raffinatestream and the continual use of feed and desorbent streams. Onepreferred embodiment of this process utilizes what is known in the artas the simulated moving-bed counter-current flow system. The operatingprinciples and sequence of such a flow system are described in U.S. Pat.No. 2,985,589 incorporated herein by reference thereto. In such asystem, it is the progressive movement of multiple liquid access pointsdown an adsorbent chamber that simulates the upward movement ofadsorbent contained in the chamber. Only four of the access lines areactive at any one time; the feed input stream, desorbent inlet stream,raffinate outlet stream, and extract outlet stream access lines.Coincident with this simulated upward movement of the solid adsorbent isthe movement of the liquid occupying the void volume of the packed bedof adsorbent. So that counter-current is maintained, a liquid flow downthe adsorbent chamber may be provided by a pump. As an active liquidaccess point moves through a cycle, that is, from the top of the chamberto the bottom, the chamber circulation pump moves through differentzones which require different flow rates. A programmed flow controllermay be provided to set and regulate these flow rates.

The active liquid access points effectively divided the adsorbentchamber into separate zones, each of which has a different function. Inthis embodiment of my process, it is generally necessary that threeseparate operational zones be present in order for the process to takeplace although in some instances an optional fourth zone may be used.

The adsorption zone, zone 1, is defined as the adsorbent located betweenthe feed inlet stream and the raffinate outlet stream. In this zone, thefeed stock contacts the adsorbent, an extract component is adsorbed, anda raffinate stream is withdrawn. Since the general flow through zone 1is from the feed stream which passes into the zone to the raffinatestream which passes out of the zone, the flow in this zone is consideredto be a downstream direction when proceeding from the feed inlet to theraffinate outlet streams.

Immediately upstream with respect to fluid flow in zone 1 is thepurification zone, zone 2. The purification zone is defined as theadsorbent between the extract outlet stream and the feed inlet stream.The basic operations taking place in zone 2 are the displacement fromthe non-selective void volume of the adsorbent of any raffinatemateerial carried into zone 2 by the shifting of adsorbent into thiszone and the desorption of any raffinate material adsorbed within theselective pore volume of the adsorbent or adsorbed on the surfaces ofthe adsorbent particles. Purification is achieved by passing a portionof extract stream material leaving zone 3 into zone 2 at zone 2'supstream boundary, the extract outlet stream, to effect the displacementof raffinate material. The flow of material in zone 2 is in a downstreamdirection from the extract outlet stream to the feed inlet stream.

Immediately upstream of zone 2 with respect to the fluid flowing in zone2 is the desorption zone or zone 3. The desorption zone is defined asthe adsorbent between the desorbent inlet and the extract outlet stream.The function of the desorption zone is to allow a desorbent materialwhich passes into this zone to displace the extract component which wasadsorbed upon the adsorbent during a previous contact with feed in zone1 in a prior cycle of operation. The flow of fluid in zone 3 isessentially in the same direction as that of zones 1 and 2.

In some instances, an optional buffer zone, zone 4, may be utilized.This zone, defined as the adsorbent between the raffinate outlet streamand the desorbent inlet stream, if used, is located immediately upstreamwith respect to the fluid flow to zone 3. Zone 4 would be utilized toconserve the amount of desorbent utilized in the desorption step since aportion of the raffinate stream which is removed from zone 1 can bepassed into zone 4 to displace desorbent material present in that zoneout of that zone into the desorption zone. Zone 4 will contain enoughadsorbent so that raffinate material present in the raffinate streampassing out of zone 1 and into zone 4 can be prevented from passing intozone 3, thereby contamininating extract stream removed from zone 3. Inthe instances in which the fourth operational zone is not utilized, theraffinate stream passed from zone 1 to zone 4 must be carefullymonitored in order that the flow directly from zone 1 to zone 3 can bestopped when there is an appreciable quantity of raffinate materialpresent in the raffinate stream passing from zone 1 into zone 3 so thatthe extract outlet stream is not contaminated.

A cyclic advancement of the input and output streams through the fixedbed of adsorbent can be accomplished by utilizing a manifold system inwhich the valves in the manifold are operated in a sequential manner toeffect the shifting of the input and output streams, thereby allowing aflow of fluid with respect to solid adsorbent in a counter-currentmanner. Another mode of operation which can effect the counter-currentflow of solid adsorbent with respect to fluid involves the use of arotating disc valve in which the input and output streams are connectedto the valve and the lines through which feed input, extract output,desorbent input and raffinate output streams pass are advanced in thesame direction through the adsorbent bed. Both the manifold arrangementand disc valve are known in the art. Specifically, rotary disc valveswhich can be utilized in this operation can be found in U.S. Pat. Nos.3,040,777 and 3,422,848. Both of the aforementioned patents disclose arotary type connection valve in which the suitable advancement of thevarious input and output streams from fixed sources can be achievedwithout difficulty.

In many instances, one operational zone will contain a much largerquantity of adsorbent than some other operational zone. For instance, insome operations the buffer zone can contain a minor amount of adsorbentas compared to the adsorbent required for the adsorption andpurification zones. It can also be seen that in instances in whichdesorbent is used which can easily desorb extract material from theadsorbent that a relatively small amount of adsorbent will be needed ina desorption zone as compared to the adsorbent needed in the buffer zoneor adsorption zone or purification zone or all of them. Since it is notrequired that the adsorbent be located in a single column, the use ofmultiple chambers or a series of columns is within the scope of theinvention.

It is not necessary that all of the input or output streams besimultaneously used, and in fact, in many instances some of the streamscan be shut off while others effect an input or output of material. Theapparatus which can be utilized to effect the process of this inventioncan also contain a series of individual beds connected by connectingconduits upon which are placed input or output taps to which the variousinput or output streams can be attached and alternately and periodicallyshifted to effect continuous operation. In some instances, theconnecting conduits can be connected to transfer taps which during thenormal operations do not function as a conduit through which materialpasses into or out of the process.

It is contemplated that at least a portion of the extract output streamwill pass into a separation means wherein at least a portion of thedesorbent material can be separated to produce an extract productcontaining a reduced concentration of desorbent material. Preferably,but not necessary to the operation of the process, at least a portion ofthe raffinate output stream will also be passed to a separation meanswherein at least a portion of the desorbent material can be separated toproduce a desorbent stream which can be reused in the process and araffinate product containing a reduced concentration of desorbentmaterial. The separation means will typically be a fractionation columnor an evaporator, the design and operation or either being well known tothe separation art.

Reference can be made to D. B. Broughton U.S. Pat. No. 2,985,589, and toa paper entitled "Continuous Adsorptive Processing --A New SeparationTechnique" by D. B. Broughton presented at the 34th Annual Meeting ofthe Society of Chemical Engineers at Tokyo, Japan, on Apr. 2, 1969, forfurther explanation of the simulated moving-bed counter-current processflow scheme.

A dynamic testing apparatus is employed to test various adsorbents witha particular feed mixture and desorbent material to measure theadsorbent characteristics of adsorptive capacity, selectivity andexchange rate. The apparatus consists of an adsorbent chamber ofapproximately 70 cc volume having inlet and outlet portions at oppositeends of the chamber. The chamber is contained within a temperaturecontrol means and, in addition, pressure control equipment is used tooperate the chamber at a constant predetermined pressure. Quantitativeand qualitative analytical equipment such as refractometers,polarimeters and chromatographs can be attached to the outlet line ofthe chamber and used to detect quantitatively or determine qualitativelyone or more components in the effluent stream leaving the adsorbentchamber. A pulse test, performed using this apparatus and the followinggeneral procedure, is used to determined selectivities and other datafor various adsorbent systems. The adsorbent is filled to equilibriumwith a particular desorbent material by passing the desorbent materialthrough the adsorbent chamber. At a convenient time, a pulse of feedcontaining known concentrations of a tracer and of a particular ketoseor aldose or both all diluted in desorbent is injected for a duration ofseveral minutes. Desorbent flow is resumed, and the tracer and theketose and aldose are eluted as in a liquid-solid chromatographicoperation. The effluent can be analyzed on-stream or alternativelyeffluent samples can be collected periodically and later analyzedseparately by analytical equipment and traces of the envelopes ofcorresponding component peaks developed.

From information derived from the test adsorbent, performance can berated in terms of void volume, retention volume for an extract or araffinate component, selectivity for one component with respect to theother, the rate, the rate of desorption of an extract component by thedesorbent and the extent of silica contamination of the extract andraffinate stream. The retention volume of an extract or a raffinatecomponent may be characterized by the distance between the center of thepeak envelope of an extract or a raffinate component and the peakenvelope of the tracer component or some other known reference point. Itis expressed in terms of the volume in cubic centimeters of desorbentpumped during this time interval represented by the distance between thepeak envelope. Selectivity, (B), for an extract component with respectto a raffinate component may be characterized by the ratio of thedistance between the center of the extract component peak envelope andthe tracer peak envelope (or other reference point) to the correspondingdistance between the center of the raffinate component peak envelope andthe tracer peak envelope. The rate of exchange of an extract componentwith the desorbent can generally be characterized by the width of thepeak envelopes at half intensity. The narrower the peak width the fasterthe desorption rate.

To further evaluate promising adsorbent systems and to translate thistype of data into a practical separation process requires actual testingof the best system in a continuous counter-current moving-bed orsimulated moving-bed liquid-solid contacting device. The generaloperating principles of such a device are as described hereinabove. Aspecific laboratory-size apparatus utilizing these principles isdescribed in deRosset et al U.S. Pat. No. 3,706,812. The equipmentcomprises multiple adsorbent beds with a number of access lines attachedto distributors within the beds and terminating at a rotary distributingvalve. At a given valve position, feed and desorbent are beingintroduced through two of the lines and the raffinate and extractstreams are being withdrawn through two more. All remaining access linesare inactive and when the position of the distributing valve is advancedby one index all active positions will be advanced by one bed. Thissimulates a condition in which the adsorbent physically moves in adirection counter-current to the liquid flow. Additional details on theabovementioned adsorbent testing apparatus and adsorbent evaluationtechniques may be found in the paper "Separation of C₈ Aromatics byAdsorption" by A. J. deRosset, R. W. Neuzil, D. J. Korous, and D. H.Rosback presented at the American Chemical Society, Los Angeles, Calif.,Mar. 28 through Apr. 2, 1971.

Although both liquid and vapor phase operations can be used in manyadsorptive separation processes, liquid-phase operation is required forthis process because of the lower temperature requirements and becauseof the higher yields of extract product that can be obtained withliquid-phase operation over those obtained with vapor-phase operation.Adsorption conditions will include a temperature range of from about 20°C. to about 200° C. with about 20° C. to about 100° C. being morepreferred and a pressure range of from about atmospheric to about 500psig. with from about atmospheric to about 250 psig. being morepreferred to insure liquid phase. Desorption conditions will include thesame range of temperatures and pressures as used for adsorptionconditions.

The size of the units which can utilize the process of this inventioncan vary anywhere from those of pilot-plant scale (see for example ourassignee's U.S. Pat. No. 3,706,812) to those of commercial scale and canrange in flow rates from as little as a few cc an hour up to manythousands of gallons per hour.

The following examples are presented to illustrate my invention and arenot intended to unduly restrict the scope and spirit of the claimsattached hereto.

EXAMPLE I

The purpose of this example is to illustrate the method of manufactureof two adsorbents having water permeable organic binders, the firsthaving a binder comprising cellulose acetate, and the second, which isthe adsorbent of the present invention, having a binder comprisingcellulose acetate butyrate. The adsorbents were each prepared by thefollowing steps:

(1) Na-Y type zeolite powder was mixed with the organic polymer.

(2) An organic solvent (acetic acid in the case of the cellulose acetatebutyrate) was added to the powder mixture slowly and with mulling toobtain an extrudable mixture.

(3) The extrudable mixture was extruded into an extrudate.

(4) The extrudate was dried at 65° C.

(5) The dried extrudate was granulated and screened so as to obtainparticles sized from 30 to 60 mesh.

(6) The cations occupying exchangeable cationic sites in the zeolitecontained in the particles were ion exchanged with calcium ions bycontacting the particles with an aqueous solution of calcium chloride,washing the particles with fresh deionized water and air, and drying theparticles at room temperature.

EXAMPLE II

The two adsorbent samples obtained in Example I were subjected to anattrition resistance test. In this test the sample is placed on screen,having a certain mesh or number of openings per inch, with a certainnumber of uniform size coins. The screen is covered, placed in a sieveshaker and shaken for 30 minutes. The increase in the amount of finesthrough the screen, based on recovered samples, over the amount ofsample that passes through the screen in a subsequent test withoutcoins, is calculated to be the weight percent attrition. Also subjectedto the attrition resistance test was a conventional adsorbent comprisingcalcium ion exchanged Y zeolite with a clay binder comprising 20% of theadsorbent.

Following are the results of the attrition resistance tests as well asthe measured specific gravities of the three adsorbents:

    ______________________________________                                                 Con-                                                                          ventional          Cellulose                                                  Clay   Cellulose   Acetate                                                    Bound  Acetate Binder                                                                            Butyrate Binder                                   ______________________________________                                        Attrition through                                                             a 50 mesh screen                                                                         6.2 wt. %                                                                              3.9 wt. %   1.5 wt. %                                     Attrition through                                                             a 60 mesh screen                                                                         4.8 wt. %                                                                              2.2 wt. %   0.8 wt. %                                     Piece Density                                                                            1.270    1.224       1.284                                         ______________________________________                                    

The data clearly illustrates the startling effect achieved by myinvention. The attrition of the cellulose acetate butyrate boundadsorbent is less than one-half of that of the cellulose acetate boundadsorbent and less than one-quarter of that of the conventional claybound adsorbent.

The significance of the higher piece density of the cellulose acetatebutyrate bound adsorbent is not certain, but, without being limited toany theory, it is believed that the cellulose acetate butyrate has agreater tendency to fill the macropores of the adsorbent, which accountsfor its higher specific gravity, and which is reflected by the superiorstrength of the adsorbent.

EXAMPLE III

This example sets forth the results of a long term stagnant aqueousstorage test of the adsorbents of Example I. In this test 250 cc of eachadsorbent was placed in a container with 1000 cc of distilled water. Thetwo containers were then placed in an oven for storage at 76° C. After30 days storage the decanted solution from each container was analyzedand the following results were obtained:

    ______________________________________                                                    Components Analyzed (wt. ppm)                                                 Si      Al        Na       Ca                                     ______________________________________                                        Solution From                                                                 Cellulose Acetate                                                                           128       <1.0      44     8.8                                  Solution From                                                                 Cellulose Acetate                                                             Butyrate      159       <1.0      28     1.1                                  ______________________________________                                    

The data shows that far less of the exchanged calcium ion is lost to theaqueous medium from the cellulose acetate butyrate bound adsorbent. Thisis very important, because when the adsorbent is used in a separationprocess additional calcium ion is added to the bed to make up for theloss in order to maintain selectivity. The need for calcium ion additionwould be substantially alleviated by use of the adsorbent of myinvention.

The reason why the silicon concentration of the aqueous medium is higherfor the cellulose acetate butyrate bound adsorbent test is not knownpositively, but it is suspected that a small amount of undissolvedsilica dust was inadvertently taken up with the portion of the solutionanalyzed.

The decanted solutions were further analyzed. The solution from thecellulose acetate bound adsorbent sample was analyzed for acetic acid,and the solution from the cellulose acetate butyrate bound adsorbent wasanalyzed for acetic acid and butyric acid. The results of the formeranalysis were 299 wt. ppm of acetic acid, from which it was calculatedthat about 0.4 wt.% of the acetyl group originally in the sample (40wt.% of the sample) went into solution. The results of the latteranalysis were 62 wt. ppm of acetic acid and 39 wt. ppm of butyric acid,from which it was calculated that about 0.3 wt.% of the acetyl group andabout 0.1 wt.% of the butyryl group originally in the sample (the samplewas 13.5 wt.% acetyl group and 37.0 wt.% butyrate group) went intosolution.

The last mentioned data indicates that the cellulose acetate butyratebinder of the adsorbent of the present invention is substantially moreresistant to hydrolyzation than the cellulose acetate binder.

EXAMPLE IV

A long term aqueous storage test was repeated. This test was similar tothat of Example III, except that its duration was for 15 days at 85° C.and the container for each adsorbent was swirled once each day. Twoseparate tests were made of the cellulose acetate butyrate boundadsorbent. Following are the results:

    ______________________________________                                                   Components Analyzed (wt. ppm)                                                 Ca      Na       Al        Si                                      ______________________________________                                        Cellulose Acetate                                                                          41        59       ≦1.3                                                                           210                                   Cellulose Acetate                                                             Butyrate (#1)                                                                              4.9       51       ≦1.3                                                                           161                                   Cellulose Acetate                                                             Butyrate (#2)                                                                              5.9       53       ≦1.3                                                                           190                                   ______________________________________                                    

Again, the data shows that far less of the exchanged calcium ion is lostto the aqueous medium from the cellulose acetate butyrate boundadsorbent. This data, however, also shows less silica dissolution. It isassumed that in this case there was avoidance of the inclusion of silicadust in the solution to be analyzed.

EXAMPLE V

This example sets forth the results of tests of the adsorbents ofExample I and a conventional 20 wt.% clay bound calcium ion exchangeadsorbent in the dynamic testing apparatus hereinbefore described todetermine the performance of each such adsorbent with regard to theadsorptive separation of the individual components of an aqueoussolution of a mixture of components.

The adsorbents were tested in a 70 cc straight column maintained atconditions of 60° C. and 50 psig pressure using pure water having a pHof 7.0 as the desorbent material. The sequence of operations for eachtest were as follows. Desorbent material was continuously run throughthe column containing the adsorbent at a nominal liquid hourly spacevelocity (LHSV) of about 1.0. At a convenient time desorbent flow wasstopped, a 4.7 cc sample of 10 wt.% fructose in water was injected intothe column via a sample loop and the desorbent flow was resumed. Theemergent sugar was detected by means of a continuous refractometerdetector and a peak envelope trace was developed. Another pulsecontaining 10 wt.% glucose was similarly run as was a pulse of deuteriumoxide. Deuterium oxide has a different index of refraction than doeswater and thus deuterium oxide can be detected with the refractometer inthe same way as is done for the sugars. The use of a feed pulsecontaining deuterium oxide therefore permits calculation of adsorbentselectivity for an extract component (fructose) with respect to water. Awater solution of sucrose was also injected to serve as a tracer fromwhich the void volume of the adsorbent bed could be determined. Thus foreach adsorbent tested four peak traces were developed, one for glucose,one for fructose, one for deuterium oxide and one for sucrose. Theretention volume for glucose was calculated by measuring the distancefrom time zero or the reference point to the midpoint of the glucosepeak and subtracting the distance representing the void volume of theadsorbent obtained by measuring the distance from the same referencepoint to the midpoint of the benzene peak. In a similar manner retentionvolumes for fructose and deuterium oxide were obtained. Theselectivities of an adsorbent for fructose with respect to glucose andfor fructose with respect to water are the quotients obtained bydividing the fructose retention volume by the glucose retention volumeand by dividing the fructose retention by the deuterium oxide retentionvolume respectively. The results for these pulse tests are as follows:

    ______________________________________                                                                     Cellulose                                                  Con-   Cellulose   Acetate                                                    ventional                                                                            Acetate Bound                                                                             Butyrate Bound                                   ______________________________________                                        Half Widths                                                                   Fructose    14       13.79       13.75                                        Glucose     12       12.26       12.06                                        Sucrose     12.6     12.81       12.46                                        D.sub.2 O   10       11.08       9.71                                         Retention Volumes                                                             Fructose    13.2     10.41       11.11                                        Glucose     2.4      1.96        2.28                                         D.sub.2 O   12.8     12.22       13.49                                        F/G         5.5      5.32        4.86                                         F/D.sub.2 O 1.03     0.85        0.82                                         ______________________________________                                    

The above data illustrates that the adsorption performance of theadsorbent of my invention is substantially the same as the clay boundand cellulose acetate bound adsorbents.

The adsorbent of my invention thus achieves the advantage of greaterattrition resistance without sacrifice of adsorption performance.

I claim as my invention:
 1. An adsorbent comprising a zeolitecrystalline aluminosilicate suitable for use in a process for theseparation of a component from a feed mixture comprising an aqueoussolution of a mixture of components by contacting said solution withsaid adsorbent, the silicon constituent of said adsorbent tending todissolve in said solution resulting in the undesirable disintegration ofsaid crystalline aluminosilicate, the adsorbent additionally containinga water permeable binder material comprising cellulose acetate butyratewhich substantially reduces the extent of dissolution of said siliconconstituent and the extent of said disintegration of said adsorbent. 2.The adsorbent of claim 1 further characterized in that said crystallinealuminosilicate is selected from the group consisting of X zeolites andY zeolites.
 3. The adsorbent of claim 2 further characterized in thatsaid crystalline aluminosilicate contains cations at exchangeablecationic sites selected from the group consisting of alkali metals andalkali earth metals.
 4. A method for the manufacture of an adsorbentcomprising crystalline aluminosilicate and a water permeable bindercomprising cellulose acetate butyrate suitable for use in a process forthe separation of a component from a feed mixture comprising an aqueoussolution of a mixture of components, which method comprises:(a) mixingtogether a powder of zeolitic crystalline aluminosilicate, a powder ofsaid cellulose acetate butyrate binder and a liquid organic solvent toform a malleable mixture; (b) forming said malleable mixture intodiscrete formations; (c) removing said solvent from said formations toobtain hard dry formations; and (d) breaking said hard dry formationsinto particles of desired sizes.
 5. The method of claim 4 furthercharacterized in that in step (a) powders of said crystallinealuminosilicate and said binder are first mixed together to obtain apowder mixture, and said liquid organic solvent is then added to saidpowder mixture to obtain said malleable mixture.
 6. The method of claim4 further characterized in that in step (a) said powder of said binderis first dissolved in said organic solvent to obtain a solution, andsaid powder of said crystalline aluminosilicate is then added to saidsolution to obtain said malleble mixture.
 7. The method of claim 4further characterized in that in step (c) said solvent is removed fromsaid formations by first washing said formations with water and thendrying said formations at a temperature not exceeding about 140° C. 8.The method of claim 4 further characterized in that in step (c) saidsolvent is removed from said formations by drying said formations at atemperature not exceeding about 140° C.
 9. The method of claim 4 furthercharacterized in that in step (d) said desired sizes of said particlesis such that said particles will pass through a No. 16 screen and beretained on a No. 80 screen.
 10. The method of claim 4 furthercharacterized in that said crystalline aluminosilicate is selected fromthe group consisting of X zeolites and Y zeolites.
 11. The method ofclaim 10 further characterized in that cations at exchangeable cationicsites on said crystalline aluminosilicate in said particles areexchanged with cations selected from the group consisting of alkalimetals and alkali earth metals.
 12. The method of claim 4 furthercharacterized in that the content of said cellulose acetate butyrate insaid particles is from about 2.0 wt.% to about 50.0 wt.%.
 13. The methodof claim 4 further characterized in that said liquid organic solventcomprises acetic acid, p-dioxane, methylethyl ketone, acetone,2-heptanone, or 5-methyl-2-hexanone.
 14. The method of claim 4 furthercharacterized in that in step (b) said forming is effected by extrusion.